Roof system and method of fabrication and installation

ABSTRACT

In a roof system having exceptional insulating value, high density polyurethane foam or extruded polystyrene is used to form molded panels of predetermined size, shape and ornamental configuration. A non-skid primer coat is applied to the top surfaces and sides of the panels at the time of manufacture. A fabric layer or polyester mesh may be embedded in the bottom of the molded foam panels to enhance adhesion characteristics. During installation, the panels are set in a layer of low rise foam adhesive that is applied to the underlying roof deck or other surface (e.g., plywood, concrete, roofing felts, or spray foam), thereby avoiding the use of penetrating fasteners while enhancing wind uplift resistance. The panels may include interlocking structure for side-by-side and/or overlapping installation. Edges of the foam panels that need to be cut for fitting at valleys, hips, ridges, etc. are repaired in the field using factory supplied fabric and coating. After complete installation of the panels, a final topcoat composition such as, but not limited to, acrylic epoxy, silicon, or polyurea is applied to seal the roof system and provide a select roof color and desired grade.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to foam panel roof systems and, more particularly, to a roof system and method of fabrication and installation of foam roof panels without the use of penetrating fasteners.

2. Discussion of the Related Art

In residential and commercial steep slope roof construction, roofing tiles or shingles are usually installed on top of roofing felts with the use of mechanical fasteners (e.g., nails). Typically, a layer of tar is first applied to the roof deck (e.g., plywood) in order to seal cracks and gaps. The roofing felts are applied using tin tags and nails that penetrate the felts, tar and roof deck. Thereafter, the tiles or shingles are installed using mechanical fasteners that also penetrate the entire roof structure. The use of penetrating fasteners for roof installations presents a number of concerns and potential problems. In particular, the use of a large number of mechanical fasteners penetrating the roof deck compromises the watertight integrity of the roof system. Moreover, spot attachment of tiles and shingles using mechanical fasteners results in limited strength against uplift forces experienced during high wind conditions, particularly hurricanes. Additionally, the weight of conventional roofing tiles, typically made of ceramic, cast concrete or clay, renders them extremely hazardous as projectiles in a hurricane.

In the past, various foam roofing tiles or panels have been proposed as an alternative to conventional ceramic and/or cast concrete tiles or wood shingles. Many of these proposed roofing tiles and panels have a hard plastic outer shell and a foam core. Examples of foam roofing panels in the related art are disclosed in the U.S. Patents to: Gleason et al., U.S. Pat. No. 4,279,106; Gadsby, U.S. Pat. No. 3,899,855; Pavia, Jr., U.S. Pat. No. 5,125,805; and Kirkhuff, U.S. Pat. No. 4,065,899. All of these foam core roofing panels are designed for installation using penetrating mechanical fasteners, which presents the several problems noted above. Moreover, the foam core panel systems in the related art do not allow for easily repairing cut or damaged tiles at the installation site in a cost effective manner.

The insulation methods used in conventional steep slope roof structures presents further problems and concerns. Typically, insulation is applied on the inside of the roof structure, under the roof deck, such as in a crawl space or attic. This has the effect of trapping heat between the roof deck and the roofing tiles. Over time, the high temperature below the tiles, as a result of trapped heat, causes premature failure of the roof system.

Accordingly, in view of the many problems and concerns associated with roofing systems and installation methods in the related art, there remains an urgent and definite need for an improved roof system and method of fabrication and installation that eliminates the need of penetrating fasteners and improves insulating values and wind uplift strength, while remaining cost effective and esthetically appealing.

OBJECTS AND ADVANTAGES OF THE INVENTION

Considering the foregoing, it is a primary object of the present invention to provide an affordable and architecturally appealing foam roof panel system and method of fabrication and installation for use in the residential and commercial steep slope roof market, and wherein the entire system is installed without the use of any penetrating fasteners.

It is a further object of the present invention to provide a foam roof panel system and method of fabrication and installation that allows for ease of installation and field modifications to the foam roof panels.

It is a further object of the present invention to provide an improved foam roof panel system and method of fabrication and installation that provides for field finishes that allow the owner/customer the option of selecting the appropriate top coat covering, including color and grade, according to the customer's budget, personal preference and needs.

It is still a further object of the present invention to provide an improved foam roof panel system and method of fabrication and installation that provides exceptional insulating value while offering aesthetically pleasing panel designs.

It is still a further object of the present invention to provide an improved foam roof panel system and method of fabrication and installation that provides tremendous uplift strength and resistance to high wind forces, particularly during hurricanes.

It is yet a further object of the present invention to provide an improved foam roof panel system and method of fabrication and installation that is lightweight, stronger, and safer during hurricanes.

It is still a further object of the present invention to provide an improved foam roof panel system and method of fabrication and installation that provides a useful life that is considerably longer than conventional steep slope roof systems.

It is yet a further object of the present invention to provide an improved foam roof panel system and method of fabrication and installation that is relatively easy to install, and easily repaired and maintained in the field in a cost effective manner.

These and other objects and advantages of the present invention are more readily apparent with reference to the detailed description and accompanying drawings.

SUMMARY OF THE INVENTION

The present invention is directed to a roof system and method of fabrication and installation for use on residential and commercial sloped roofs. The roof system includes individual panels molded with a high density polyurethane foam or extruded polystyrene. The panels are molded to predetermined sizes, shapes and ornamental configurations. The foam core of the roofing panels provides exceptionally high insulating values. During manufacture, a non-skid primer coat is applied to the top surfaces and sides of the panels. A coated wire mesh may be embedded in the mold, within the foam core, to provide additional strength and resistance to warping, thereby maintaining the shape of the panel configuration. A fabric layer or polyester mesh may be embedded in the bottom of the molded foam panels to enhance adhesion characteristics. Additionally, the bottom surface may be configured with grooves or other irregular surface patterns to improve adhesion. During installation, the panels are set in a layer of low rise foam adhesive that is applied to the underlying roof deck or other surface (e.g., plywood, concrete, roofing felts or spray foam), thereby avoiding the use penetrating fasteners while enhancing wind uplift resistance. Installation over spray foam, such as polyurethane spray foam or other approved foam insulation may be performed in conjunction with the use of deck leveling guides to minimize waviness and to maintain uniform foam insulation thickness over the underlying roof deck.

The molded foam panels may be formed to include interlocking structure for side-by-side and/or overlapping installation. Edges of the molded foam panels that need to be cut for fitting at valleys, hips, ridges, etc. can be repaired in the field using factory supplied fabric and coating. After complete installation of the molded foam panels, a final topcoat composition such as, but not limited to, acrylic epoxy, silicon, or polyurea is applied to seal the roof system and provide a select roof color and desired grade.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature of the present invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a cross-sectional view showing the roof system of the present invention installed on a plywood roof deck;

FIG. 2 is an isolated cross-sectional view taken from the area indicated in FIG. 1;

FIG. 3 is a top plan view showing a pair of molded foam roof panels adapted for overlapping, interlocking attachment in accordance with one preferred embodiment of the invention;

FIG. 4 is an isolated elevational view showing the overlapping edges of the molded foam roof panels of FIG. 3;

FIG. 5 is an isolated elevational view showing the overlapping edges of the roof panels attached in overlapping, interlocking engagement;

FIG. 6 is a top plan view illustrating a further embodiment of the molded foam roof panels and method of side-by-side interlocking attachment;

FIG. 7 is an isolated perspective view showing the side edges of the molded foam roof panels of FIG. 6;

FIG. 8 is an isolated perspective view showing the side edges of the molded foam roof panels of FIG. 6 in interlocked, side-by-side engagement;

FIG. 9 is an isolated cross-sectional view showing a further embodiment of the overlapping structure of the molded foam roof panels installed according to the system of the present invention on a plywood roof deck;

FIG. 10 is a perspective view, in cut-away, showing a further embodiment of the molded foam roof panels including an optional solar panel;

FIG. 11 is a general schematic illustration showing a further embodiment of the molded foam roof panel of the present invention having a series of electrically interconnected solar panels; and

FIG. 12 is a cross-sectional view of the molded foam roof panel of FIG. 11 illustrating a solar panel tray molded within the top of the roof panel for accommodating the solar cell.

Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The roof system of the present invention is shown throughout the several views of the drawings and is generally indicated as 10. The roof system 10 uses individual roofing panels 20 that are molded with a high density polyurethane foam or extruded polystyrene foam core 22. The panels 20 are molded in various sizes, shapes and configurations according to the desired aesthetic appearance of the roof. The molded panels 20 may also be formed as ridge caps, as well as other accessory components for fitting at unique intersections of the roof, terminations with walls, valleys, hips, ridges, etc. The foam core 22 of the roofing panels 20 provides exceptionally high insulating values well beyond that of conventional roofing tiles and shingles. During manufacture, a non-skid primer coat 24, such as a cement acrylic coating composition, is applied to the top surfaces and side edges of the molded panels. To enhance the adhesion characteristics, the bottom side 26 of the molded panels 20 may be provided with a fabric layer or polyester mesh 28 that is adhered to or embedded in the foam 22. Alternatively, the bottom side 26 of the panels may be provided with a grooved or irregular surface configuration to allow for improved adhesion at installation. The foam core 22 may further be provided with a coated wire mesh 30 embedded within the foam core to provide additional strength and resistance to warping. The embedded wire mesh 30 helps to maintain the shape of the molded panel 20, particularly when the panel is formed in unique or unusual configurations.

The molded foam panel 20 may be designed for overlapping installation as seen FIGS. 1, 2 and 9. In this instance, the panels 20 are formed to include interlocking structure on the engaging overlapping surfaces. Specifically, the overlapping periphery of the panels may be formed for notched, flush fitting and overlapping attachment of adjacent panels, as demonstrated in FIGS. 4 and 5. In this instance, a rib or protruding flange 44 along the edge 40 of one panel is adapted for interlocking receipt within a correspondingly configured groove 46 or channel formed in the overlapping portion 42 of the adjacent panel, as seen in FIGS. 3-5. Alternatively, the panels 20 may be formed for side-by-side interlocking engagement. In this instance, the side edge 50 of one panel is provided with a protruding rib or tongue 54 for interlocking receipt within a correspondingly configured groove 56 formed in the abutting side edge 52 of an adjacently positioned panel, as shown in FIGS. 6-8. In order to cover the seam between the adjacently positioned panels, an overlapping patch panel 20 a may be provided, as seen in FIG. 6. In this instance, the top surface 60 of the panels 20 where the patch panel 20 a is to be attached may be recessed, so that when the patch panel 20 a is installed, the top surface of the patch panel lies flush with a remaining top surface of the adjacent panels.

During installation, the molded foam panels are set in a layer low rise foam adhesive 70. Referring to FIGS. 1 and 2, installation of the roof system 10 of the present invention on a sloped roof structure 100 is shown. The roof structure 100 includes a frame 110, such as trusses, with a roof deck 120, such as plywood sheets, fastened to the roof frame 110. In this example of the roof system 10, a spray foam insulation 80, such as polyurethane spray foam, is applied to the plywood roof deck. In order to maintain uniform thickness of the layer of spray foam insulation 80 over the entire roof deck 120, guide blocks 82 may be used. Specifically, elongate wood blocks 82 of desired height (e.g., 2″) are fastened to the top surface of the roof deck 120 prior to application of the spray foam insulation 80. The guide blocks 82 may be installed in transverse parallel rows spaced 2 to 3 feet apart. The layer of spray foam insulation 80 can then be applied with the guide blocks 82 serving as a height indicator to maintain uniform thickness of the applied layer of spray foam insulation 80 over the roof deck 120, while minimizing waviness commonly associated with spray foam installations.

The method of installation of the roof system 10 of the present invention consists of setting the molded foam panels 20 in a layer of low rise foam adhesive 70, as seen in FIGS. 1, 2 and 9. The low rise foam adhesive 70 may be applied over the spray foam insulation 80 or, alternatively, directly to plywood deck, concrete deck, roofing felts, or other membrane system. Use of low rise foam adhesive, or approved equivalent, provides optimal bonding of the panels 20 to the roof, providing excellent uplift strength to resist hurricane force winds.

During installation, edges of the molded foam panels 20 will need to be cut for fitting at valleys, hips, ridges, etc. The cut edges are repaired in the field using factory supplied fabric and coatings. After complete installation of the molded foam panels 20, including ridge caps and accessories at valleys, hips, ridges, etc., a final top coat composition is applied over the entire roof, coating all exposed surfaces of the panels. The top coat composition may include, but is not limited to, acrylic epoxy, silicon, or polyurea. The top coat composition is applied to seal the entire roof system and provide a select roof color and desired grade, according to the needs and budgetary constraints of the customer.

FIGS. 10-12 illustrate a further embodiment of the roof panel 20 of the present invention, wherein the roof panel incorporates one or more solar cells 90 on the top side of the panel. FIG. 12 shows a cross-section of the molded foam panel 20 including a recessed tray 92 for receiving a solar cell 90 that is anchored to the foam core. A protective solar glass 94 covers solar cell 90 and is flush with the top surface of the panel 20. FIG. 11 illustrates a molded foam panel 20 incorporating a plurality of solar cells 90 within in recessed trays 92, as shown in FIG. 12, with each of the solar cells 90 electrically connected in series by conductors 96 extending through the foam core. Male and female 97, 98 connectors are provided at opposite ends of the panel 20 for electrical connection with adjacently installed panels.

While the present invention has been shown and described in accordance with preferred and practical embodiments thereof, it is recognized that departures from the instant disclosure are fully contemplated within the spirit and scope of the invention. 

1. A panel system for installation on an exterior surface of a building structure, said system comprising: a plurality of individual panels each of predetermined size, shape and configuration, and each of said plurality of panels including: a core molded with a foam composition into said predetermined size, shape and configuration; a primer composition applied to at least a portion of exposed surfaces of said molded foam core, including a top surface and side surfaces, and said applied primer composition defining and outer shell to at least partially encapsulate said molded foam core; a low rise foam adhesive composition applied as a layer over the exterior surface of the building structure for installation and bonding attachment of said plurality of individual panels in covering relation to the underlying layer of low rise foam adhesive and the exterior surface of the building structure; and a top coat composition applied to said installed plurality of individual panels for coloring and sealing the installed panel system.
 2. The panel system according to claim 1 wherein said foam composition is high density polyurethane foam.
 3. The panel system according to claim 1 wherein said foam composition is polystyrene.
 4. The panel system according to claim 1 wherein at least some of said plurality of individual panels include a fabric layer on a bottom side of said molded foam core for enhancing adhesion to said layer of low rise foam adhesive.
 5. The panel system according to claim 1 wherein at least some of said plurality of individual panels include a mesh material on a bottom side of said molded foam core for enhancing adhesion to said layer of low rise foam adhesive.
 6. The panel system according to claim 1 wherein said top coat composition is an acrylic epoxy.
 7. The panel system according to claim 1 wherein said top coat composition is silicon.
 8. The panel system according to claim 1 wherein said top coat composition is polyurea.
 9. The panel system according to claim 1 further comprising: a layer of spray foam insulation applied over the exterior surface of the building structure and between said exterior surface and said layer of low rise foam adhesive composition.
 10. A method of fabrication and installation of a panel system on an exterior surface of a building structure, said method comprising the steps of: forming a plurality of individual panels of predetermined size, shape and configuration by first molding a core into said predetermined size, shape and configuration using a foam composition, and then applying a primer composition to at least a portion of exposed surfaces of said molded foam core, including a top surface and side surfaces of said molded foam core; applying a layer of a low rise foam adhesive composition over the exterior surface of the building structure; placing the plurality of individual panels on top of the layer of low rise foam adhesive composition and positioning the plurality of individual panels in covering relation to the underlying layer of low rise foam adhesive composition and the exterior surface of the building structure; and applying a top coat composition of select color and grade to exposed surfaces of the plurality of individual panels for coloring and sealing the installed panel system.
 11. The method according to claim 10 comprises the further steps of: cutting at least some of the plurality of individual panels prior to said step of placing the cut panels over said layer of low rise foam adhesive composition in order to fit said cut panels at edges, valleys, hips, ridges, wall junctions and other areas of the exterior surface of the building structure; applying a primer composition to said cut panels to cover exposed areas of said molded foam core.
 12. The method according to claim 11 wherein said step of applying said top coat composition is accomplished by spraying said top coat composition over the exposed surfaces of said plurality of individual panels of the installed panel system.
 13. The method according to claim 12 wherein said foam composition of said molded foam core is a high density poly urethane foam composition.
 14. The method according to claim 12 wherein said foam composition of said molded foam core is polystyrene.
 15. The method according to claim 12 wherein said top coat composition is acrylic epoxy.
 16. The method according to claim 12 wherein said top coat composition is silicon.
 17. The method according to claim 12 wherein said top coat composition is polyurea.
 18. The method according to claim 12 comprising the further step of: applying a layer of spray foam insulation over the exterior surface of the building structure prior to said step of applying said layer of low rise adhesive composition. 